Expansion process and apparatus for refining hydrocarbon materials



Jan. 3, 1928;

v R. K. COLLINS EXPANSION PROCESS AND APPARATUS FOR REFINING HYDROCARBON MATERIALS Filed May 23, 1922 3 Sheets-Sheet 1 inventor,

Jar 1. 3,1921; v 1,654,578

R. K. COLLINS EXPANSION PROCESS AND APPARATUS FOR REFINING HYDROGARBON MATERIALS Filed May 23, 1922 3 Shegts-Sheet .2

R115 5 211 K. cl'L'L-L'ns Jan. 3, 1928.

EXPANSION PROCESS 1,654,578 R. K. COLLINS AND APPARATUS FOR REFINING HYDROCARBON MATERIALS Filed May 23, 1922 3 Sheets-Sheet 3 u 5 5 EU. K. l1 all-L115 Patented J an. 3,. 1928.

UNITED STATES PATENT OFFICE.

RUSSELL K. COLLINS, 0F FORT WORTH, TEXAS, ASSIGNOR, BY MESNE ASSIGNMENTS,

TO COLLINS PROCESS, INC., OF WILMINGTON, DELAWARE, A CORPORATION OF DEL- AWARE.

EXPANSION PROCESS .AND APPARATUS FOR REFINING HYDROCARBON MATERIALS.

Application filed May 23, 1922. Serial No. 563,136.

This invention relates to a new and improved process for the refining of hydrocarbon materials.

A further object ofthe invention is the provision of an improved process for the refining of hydro-carbon fluids by destructive distillation, having particular regard for the treatment of hydro-carbon vapors accordthe treatment of a hydro-carbon material in ing to the chemical, thermo-dynamic, and mechanical laws of physical conversion.

A further object of the invention is the 7 section, showingthe expander and its assoprovision of an improved process for the refining of hydro-carbon materials, according to an expansion method, in which certain hydro-carbon vapors are initially provided in pre-expanded state by distillation, and separated and treated in such manner as to most effectively release the constituent atoms thereof.

A further object of the invention is the provision of an improved expansion process for the refining of hydro-carbon materials, providing for the separation of the lighter, and heavier fractions of a resultant hydrocarbon product, and including an improved arrangement for treating and further refining the heavier fraction.

A'further object of the invention is the provision of an improved process for the refining of hydro-carbon material, including an improved method of treating hydro-can bon vapors with fixed hydro-carbon gases to increase the O(yield of gasoline distillate from a given b y of oil.

A further object of the invention is the provision of an improved apparatus for the refining of hydro-carbon material, which includes an improved method of treating and revaporizing a heavier fraction after destructive distillation, and co-mingling the revaporized fraction with an initial product, in such manner as to increase the yield of a desired distillate.

A further object of the invention is the provision of an improved apparatus for the refining of crude petroleum oil according to an expansion process, so arranged as to utilize the products of fuel combustion in the heating of the resultant products throughout the various steps of the process.

Other objects and advantages of this process will of course, be apparent during the following-detailed description.

in the accompanying drawings, forming a Figure 1 is a side elevation of a part of the apparatus used in the refining of hydrocarbonmaterials according to the improved expansion process.

Figure .2 is a diagrammatic view showing the various steps of the expansion process.

Figure 3 is a fragmentary view,'partly in ciated parts.

-Figure 4 is a view, partly in section, showing a dephlegmator used as a Part of the improved apparatus for refining of hydrocarbon products.

In the drawings, wherein for the purpose of illustration isshown the preferred embodiment of this invention, the letter A generically designates the improved apparatus for refining of hydro-carbon materials, and includes a still B; expander apparatus C; furnace D; dephlegmator E; back trap convertor or rerun still F; condenser G; receiving house H; pump house K; receiving tank L; and fixed gas tank M.

Referring to the still B, the same is preferably of the cylindrical horizontal type, provided with the ordinary accessories, and including a dome IO intermediate its ends into which a vapor line 11 communicates and" extends horizontally for connection to the expander C. v

The improved expander C, which is more specifically described and claimed in my copending application filed May 8, 1922, Serial No; 561,925, includes a cylindrical shaped casing 15 which is vertically positioned, and includes the side walls 16-; top wall17; and bottom wall 18. A pipe 19 communicates the vapor line 11 with the chamber 20 of the casing 15 adjacent the bottom wall 18, for supply of vapor to the chamber 20 in a manner which will be subsequently described. The casing 15 is mounted upon a conical shaped housing 21, which provides aheat chamber 22 therebelow; said housing 21 likewise being provided as a support for the back trap convert-or F in a manner which will be subsequently described in detail. Tubes or flues 25 are provided in the chamber 20 of the casing 15, arranged in parallel relation longitudinally thereof, and sup ported at their ends by the top and bottom plates 17 and 18 respectively of said casing 15, so that said tubes open at their lower ends into the chamber 22 of the housing 21, and at their upper ends into the chamber 27 of a stack 28. Perforated nickel screens 29 are provided in the chamber arranged as baffle plates therein, and suitably affixed to the inside of the casing walls 16 so that the chamber 20 is subdivided into a plurality of compartments; the baffles 29 being arranged in parallel relation to the top and bottom walls 17 and 18. An outlet pipe 30 leads from the casing 15 adjacent the top wall 17 to the dephlegmator E for the purpose of conveying vapor thereto. A pipe section 31 g is provided, communicating the vapor line 11 adjacent the connection 19 thereof with the line 30 leading to the dephlegmator E; said pipe section 31 having a cut-off valve 32 therein which may be regulated for closing when it is desired to divert vapors from still,

B into the expander C, as will be the case during the operation of the apparatus A according to the expansion process. A valve 35 may be provided in the pipe connection 19, which is normally open, although the same may be closed for cutting off communication of the vapor line 11 with the expander C. If desired, a check valve 37 may be provided in the vapor line 11, as is shown in the diagrammatic illustration of the improved process, in ordervto prevent sudden back pressure from forming on the vaporizer or still B. An automatic pressure release valve 38 may be provided in the outlet pipe 30 adjacent the expander C, for the purpose of regulating any pressure which might exist within the expander, altho such pressure is normally very low.

The furnace D is provided with its main heating chamber 39 below the vaporizer or still B, and extends longitudinally thereof;

the fire grate 40 being positioned at the forward end of said still B. A passageway 41 is, however, provided in the foundation 42 in which the furnace D is supported; said passageway 41 leading beneath the expander C and communicating into the chamber 22 of the housing 21 thereof. Draft control fines 43 may be provided in the passage-' way 41 of the foundation 42 and beneath the expander, said fines being provided for the purpose of controlling then-mount of products of combustion which may-pass from the furnace chamber 39 through the passageway 41 into the chamber 22 above described. It is obvious that by such an arrangement, the products of combustion from the fuel within the chamber 39 are not only utilized for heating the still B, but pass into the chamber 22 of. the expander housing- 21 for heating the back trap converter F; said products of combustion further passing upwardly through the various expander fines 25 for heating the hydrocarbon productwithin the casing chamberc20. The waste products of combustion finally pass through the stack 28 after being utilized for heating of the still B, back trap converter F, and expander casing 15.

Referring to the dephlegmator tower E, the same is provided for receiving the hydro-carbon vapor after destructive distillation in the expander C, performing the function of separating the lighter and heavier fractionates of the hydro-carbon.

product as is well known to those skilled in the art. The dephlegmator E includes the cylindrical shaped casing 45, which 0011]- prises the side walls 47; top wall 48; and bottom wall 49; said top and bottom walls 48 and 49 preferably being of convex formation. The pipe section 30 for conducting of vapors from the expander C has communication with the inlet opening 5 0 in the casing 45, just upwardly of the bottom wall 49, as is illustrated in Figures 1 and 4 of the drawings. An opening 51 is provided, adjacent the top wall 48, through the side wall of the casing 45, for outlet of the lighter fraction in vapor form from the dephlegmator E.

A plurality of horizontal perforated baffle plates 52 are provided within the chamber 53 of the casing 45, to subdivide the same into a plurality of compartments 54 intermediate the inlet and outlet openings 50 and 51 respectively. Each of the compartments 54 is provided with a frusto-conical shaped baffle plate 55 of sheet material, which is affixed about its entire major circumference to the interior of its compartment 54. Each baffle plate 55 is provided with a relatively large central openings 56 therein for outlet of the uncondensed fraction into the next succeedingcompartment 54.

Vapor entering the dephlegmator E from the pipe line 30 enters the lower compartment 57 just below the baffle plate 52. This vapor, as will be hereinafter more fully set forth has been converted so that the constituent parts thereof are released and ready for dephlegmation. The vapors entering from the pipe 30 will first pass through the perforations of the louver bafiie plate 52, and ride over the inner surface of the conical bafiie plate 55 in the lowermost con'lpartment 54. Due to the fact that the constituent parts of the vapor are ready for the dephlegmation action, the heavier fractionate will condense" upon the inside of the lower battle 55, as is well known, and drop into the chamber 57. The remaining vapor will pass through the opening 56 in the lower battle plate 55, and be baffled in its upward passurface of the lower conical shaped bafile plate 55, where said heavier fractionate will flow downwardly into. the circumferential groove in the lower compartment 54 about the baffle plate 55. The vapor arising into the second upper compartment 54 likewise is bafiled upon the second conical shaped baffleplate 55, and some of the heavier fractionate will condense inwardly thereon and' after dropping therefrom will flow into the passageway about the lower baffle plate 55 as above mentioned. The vapor in thus aris ing toward the outlet opening 51 will be successively baflled against thevarious conical shaped battle plates 55, so that heavier fractions having varying boiling points will individually or combined. @In the improved expansion process, herein described, it is preferred that a pipe line 59 be provided exteriorly of the casing 45, having connection with the'various compartments 54 by means 'of the couplings 60, just upwardly of the circumferential connections of each of the conical shaped bafile plates 55 with the easing 45, in order that the material condensed in the compartment 54 maybe led into the lowermost chamber 57 of the dephlegmator E, where the combined condensed fractionate maybe conveyed, as by gravity, through the drain pipe 62 into an end of the back trap converter F. If desired, a man hole cover 63 may be provided in the top Wall 48 for access to the chamber 53.

Referring to the back trap converter F, the same is transversely mounted in the housing 21 of the expander apparatus C abovedescribed, so that the ends thereof extend 'exteriorly of the housing 21, althoughthe main body portion of the back trap converter casing 64 extends through the chamber 22 for receiving the heat therefrom. The chamber 65 of the elongate converter casing 64 is adapted for rec iving the condensed fractionate from the dephlegmator E through the drain tube 62, which is connected in one end thereof as is illustrated in the drawings. A pipe line 65 likewise communicates with the converter chamber 65, adjacent the fractionate inlet tube 62; said line 65 being provided for leading fixed hydro-carbon gas into the converter F for a purpose which will be subsequently described. Superheated steam may be conveyedfrom a boiler 67 through conduits 68 for inlet into the vaporizer or still B as at 69; said conduit 68 leading for communication with the back trap converter F at an end opposite that to'which the gas line 65 is connected; The inlet of superheated steam to the chamber 65 may be controlled .in the conduit 68 by-means of a valve 70.

A pressure gauge 71 may be appropriately carried by the converter casing 64. Likewise, a drain tube or cock 72 may be provided therein. The chamber 65 is preferably provided with a plurality of perforated bafiie plates 73 arranged therein in staggered relation, so that the flow of materials within the chamber 65' is bafiied for thorough admixing thereof in order to revaporize the fractionate therein and suitably treat the same, so that it may arise through the perforated tube 76 into the chamber 20 of the expander C for admixing with the vapors therein in order to provide proper reaction of the hydro-carbon vapors.

The lighter fractions emanating from the dephlegmator E in the form of vapor are -'led through the conduit into the condenser G, which is of any approved type, such as the standard Worm and water box construction. The distilled product issues from the condenser G into the receiving housing H through a pipe'line'77. If desired, a water trap 78 may be positioned in the pipe line 77, operating in an effective manner for separation of water from the condensed fraction. The receiving house equipment is also of conventional type, and wherein the fixed gases are drawn into the gas header 78 by means of a vacuum maintained therein by the gas compressor 79. The condensed distillate passes through the run down lines 80 and into the receiving tank L. The ,gas compressor 79 is preferably operated by steam from the line 81, which is inthe super heated. steam conduit 68 above described. The fixed gases are ultimately discharged into the gas tank M, and light hydro-carbon distillates similar to those known as casing head gasoline are here collected by means of a drip trap 83. A blower 84 may be po-- sitioned in the pump house K for conducting of the fixed gases from the tank M therethrough into the back trap converter F through the conduit 65. V

Referring more particularly to the process for treating of hydro-carbon materials, the crude petroleum 'is disposed, in any appropriate manner, within the still B and heated therein from the products of combustion within the fuel chamber 39. The heating of the crude petroleum within the still B continues until the liquid molecules release their constituent parts above the liquid mass, In the form of'vapor. The vapor in its preexpanded state then passes into the vapor,

further expansion is likewise effected by the application of heat Within the expander c amber 20; said heat passing off from the flues 25. The vapors enteringthe chamber 20 spiral upwardly about the flues 25 in violent manner. The volume of gas within the chamber 20 is thus pierced, so to speak, with adjacently positioned heating flues for the even and thorough heating of the whole mass of the vapor within the expander C in the quickest manner possible. The mechanical and thermo-dynamic expansion of the vapors in the chamber 20 continues until molecular conversion takes place," releasing the lighter and more Volatile constituents from the heavier constituent molecules thereof. The resultant product flows into the dephlegmator E, where the same is treated in the manner above described, and the heavier fractionate emanating from the expander C is condensed for drain into the back trap convertor F. Due to the removal of the space restriction in the expander, so that the hydrocarbon in the vapor phase may undergo a mechanical expansion, in combination with a thorough and uniform heating of the vapor to further expand the same, molecular conversion. is quickly accomplished, without the necessity of prolonged treatment in the expander; it being thus possible to quickly treat a large quantity of the product in the vapor phase to produce the result herein defined.

It is conventional practice to rerun the heavier fractionate I after dephlegmation with separate beatings to vaporize, crack, and condense, all of which operations are independent of the original process. In .the improved expansion process of refining hydro-carbon materials, the heavier distilled fractionatc in the back trap converter is combined with superheated steam whichis injected therein by means of the conduit 68, and the same is likewise associated in the back trap converter with the fixed gases forced therein through the conduit as hereinbefore described. The vapor issuing from the perforated tube 7 6 into the chamber 20 of the expander C cooperates with the vapor in the chamber 20 which has passed therein from the vapor line 11. The process of conversion within the expander continues inconjunction with the process of hydrogenation which is brought about by the steam introduced into the expander from the vaporizer by way of the vapor line, and also from the back trap converter, in company with the fixed gases and other vapors generated therein. The breaking down of the hydro-carbon being treated within the expander into fixed gases and solid carbon is thus prevented, and the formation of the desired fractions is facilitated by the introduction of permanent or fixed gases and the superheated-steam from the boiler (57. The reactions within ,the expander are of such character asto produce a maximum yield of the desired fractions Since there is an excess of fixed gas within the expander chamber 20, there need be no breaking down of the hydro-carbon gases of the initial material supplied from the vapor line 11. On the contrary, it has been found in actual practice that the tendency for the new gaseous formation resulting from combining of the vapors from the line 11 and the vapor from the back trap convertor, absorb some of the fixed gases coming from the back trap convertor, and thereby augmenting the yield of the lighter group of hydro-carbon distil-- verter performs a function which is essen-- tially that of a small rerun still, but of greatly increased efficiency, since the distillates that it converts 0r reruns are delivered in relatively small quantities. from the dephlegmating tower without the necessity of putting the rerun through an independent conversion process. A check valvemay be provided in the drain line 62 to prevent back pressures from the convertor F reaching the dephlegmator chamber 53.

No mechanical stirrers or coke removers are needed in the expansion process herein described, as no total decomposition takes place, except at the will of the operator. For cleaning and inspection purposes, a man hole 86 may be provided in the expander chamber 15, as is illustrated in Figure 1 of the drawings.

From the foregoing? description of th apparatus and process ofthe invention herein shown and described, it can be seen that considerable fuel conservation will result in this treatment of the various hydro-carbon.

materials, in that products of combustion in the furnace D areutilized for heating the still 13, expander C, and back trap con verter F. It is an outstanding feature of this invention that the final'conversion of the hydro-carbon material for releasing of the lighter and heavier constituents thereof is effected 1n the vapor phase, at a time when the same is completely separated from theliquid hydro-carbon material. This is an improvement, taken in conjunction with the other characteristics of the expander C, as it' has been proven that in processes which retain the vaporized hydro-carbon within the container also occupied by the liquid hydro-carbon and treated to the point of conversion, the resultant product will be rela tively poor, and of low yield.

Various changes in the shape, size, and ar 'angement of parts of the apparatus herein shown and describedv for the refining of v various hydro-carbon materials may be made,

without departing from the spirit of this invention or the scope of the claims.

I claim:

1. The process of treating petroleum, which consists in distilling a hydro-carbon material in a still to provide a vapor, conducting said vapor into an expansion chamber, heating the vapor in said expansion chamber to a conversion point to release the constituent parts thereof, passing the re leased constituent parts through a dephlegmator to separate the lighter and heavier fractions, conducting the heavier fractions to a rerun chamber, treating said heavier fractions in the rerun chamber with superheated steam and a fixed hydro-carbon gas, heating the resultant product in the rerun chamber to form a vapor and conducting the vapor from said rerun chamber to said expansion chamber for conversion there-in With the vapor emanating from said still.

2. The process of treating hydro-carbon materials which consists in distilling a hydrocarbon material in a still to provide a vapor product, conducting the vapor product into an expansion chamber, heating the vapor product in said expansion chamber to a conversion point in order to release the constituent parts thereof, passing the constituent parts through a dephlegmator to separate the lighter and heavier fractions thereof, conducting the heavier fraction to a rerun chamber, treating the heavier fraction in said rerun chamber with superheated steam and fixed hydro-carbon gases, heating the resultant product in said rerun chamber with the products of combustion passing off after heating of the still to form a vapor product within said rerun chamber, and conducting the vapor product from said rerun chamber to said expansion chamber for conversion therein with the vapor therein emanating from said still.

3. The process of treating petroleum which consists in distilling a hydro-carbon material in a still to provide a vapor product, injecting superheated steam with said vapor product from said still, conducting the vapor product and superheated steam into an expansion chamber, heating the vapor product within saidsexpansion chamber to a conversion point in order to release the constituent parts thereof, passing the constituent parts through a dephlegmator to separate the lighter and heavier fractions thereof, conducting the heavier fractions to a rerun chamber, treating said heavier fractions in the rerun chamber with superheated steam and fixed hydro-carbon gases, heating the resultant product in the rerun chamber to form a vapor product, conducting said vapor product to the expansion chamber for conversion therein with the vapor emanating from said still, and passing the lighter fractions from the dephlegmator for condensation.

at. An apparatus for the treatment of hydro-carbon materials comprising a still having a chamber therein for receiving hydro-carbon materials, an expander including a chamber in communication with sald still chamber, means for heating said still,

chamber and expander whereby a vapor product may pass from said still chamber to said expansion chamber for conversion in the latter, a dephlegmator for receiving the converted product from said expander chamber, a back trap converter for receiving the heavier fraction from said dephlegmator, means for treating the fraction in said back trap converter for supplying a vapor product therefrom to said expander chamber, and condensing apparatus for receiving the lighter-fraction from the dephlegmator.

5. An apparatus for the treatment of hydro-carbon materials comprising a still including a chamber, an expander including a chamber in communication with said still, a dephlegmator communicating with said expander chamber, a back trap converter communicating with said dephlegmator and expander chamber, means for heating said still, back trap convertor, and expander chamber from the same products of combustion, and condensing apparatus leading from said dephlegmator.

6. An apparatus for treatment of hydrocarbon products comprising a still including a chamber for receiving a hydro-carbon material, heating means for said still, an expander chamber, a vapor line extending from said still chamber to the said expander chamber for conducting products of distillation from said still chamber to the expander chamber, in :ans permitting heating of said expander chamber, a dephlegmator apparatus for receiving converted vapor products after treatment in said expander chamber, a rerun container for receiving heavier fractions from said dephlegmator positioned in communication With said expanding chamber, a source of superheated steam for flow into said still chamber and rerun chamber, a source of fixed gas for feeding into-said rerun chamber, means permitting heating of said rerun container and condensing and ill) separating apparatus leading from said de.

phlegmator,

7. The expansion process of refining I hydro-carbon materials which consists in expansion compartment of a predetermined lower pressure to pernnt of a mechamcal'ex- "pansion of the hydrocarbon vapor as it enters the said compartment, subjecting the said hydrocarbon in its vapor phase only in said compartment to a heat treatment for expansion as the said vapor rises therein,

contacting outside ofa plurality of laterally spaced but substantially vertically arranged heating zones from which the heat radiates and along which the vapor passes from the lower end of the compartment to the upper end thereof,' and Withdrawing from the upper end of said compartment the desired v which consists in feeding a hydrocarbon in its vapor phase only into an expansion compartment at the lower'end of said compart- 1nent, causing said vapor to vertically ascend in said compartment in an undivided mass, withdrawing said vapor from the top of said compartment, and during tl-ievertical flow of the vapor through saidcompartment heat treating the same in its undivided mass condition at a plurality of closely spaced vertical heating zones radiating heat into said vapor mass capable of converting said vapors. v

RUSSELL K. COLLINS. 

